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We describe our practical procedure of designing thermally robust brake discs using conventional CAE. First, we review the literature describing brake judder, measurement technologies, and CAE focusing on brake discs. Second, we present some experimental results confirming what effect the basic configurations of brake discs have on thermal behaviors and the correlation between CAE simulation and physical test results. Finally, we propose a design strategy for developing thermally stable brake discs with an outer-hat configuration. We carried out a series of CAE experiments based on the Taguchi Method and determined the critical parameters for reducing the amount of coning. We also present some simplified models using classical theory regarding the strength of materials to discuss what effect the dimensional parameters have on the discs' thermal deformation.

We have constructed an original brake disc design system by standardizing, automating, and speeding up each design process. This system consists of two steps. In the first step, a designer, without professional knowledge or skills regarding CAE, can easily carry out FEA by manipulating pull-down menus, parametric design, and automated modeling and meshing. Further, our new computer program automatically identifies each eigenmode. It takes less than two hours for a complete FEA of a new design. In the second step, the developed postprocessor makes it easier and faster to compare the simulated results of many design alternatives and determine the optimum solution. Through the accumulation of vast numbers of FEA cases and tests for validation, we have obtained the knowledge of the effects of disc configurations, dimensions, and material properties on resonant frequencies and thermal deflections.